WO2024073840A1 - Coupling assembly for a solar panel, solar panel structure and solar panel system - Google Patents

Coupling assembly for a solar panel, solar panel structure and solar panel system Download PDF

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Publication number
WO2024073840A1
WO2024073840A1 PCT/CA2023/051302 CA2023051302W WO2024073840A1 WO 2024073840 A1 WO2024073840 A1 WO 2024073840A1 CA 2023051302 W CA2023051302 W CA 2023051302W WO 2024073840 A1 WO2024073840 A1 WO 2024073840A1
Authority
WO
WIPO (PCT)
Prior art keywords
solar panel
coupling assembly
rails
solar
coupling
Prior art date
Application number
PCT/CA2023/051302
Other languages
French (fr)
Inventor
Chahine GHIMOUZ
Samy BENHAMZA
Theo FREGEFOND
Original Assignee
Technologies Capsolaire Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Technologies Capsolaire Inc filed Critical Technologies Capsolaire Inc
Publication of WO2024073840A1 publication Critical patent/WO2024073840A1/en

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Classifications

    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02SGENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S40/00Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/30Electrical components
    • H02S40/36Electrical components characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02SGENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00Supporting structures for PV modules
    • H02S20/20Supporting structures directly fixed to an immovable object
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01RELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R25/00Coupling parts adapted for simultaneous co-operation with two or more identical counterparts, e.g. for distributing energy to two or more circuits
    • H01R25/14Rails or bus-bars constructed so that the counterparts can be connected thereto at any point along their length
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/50Photovoltaic [PV] energy

Definitions

  • the present disclosure relates to the field of solar panels. More specifically, the present disclosure presents a coupling assembly, structure equipped with such coupling assembly, and a solar panel system.
  • solar panels The manufacturing and deployment of solar panels is becoming an increasingly significant industrial and commercial activity, with solar energy becoming an increasingly cost-effective source of energy.
  • the combination of innovation and cost reductions makes solar panels an attractive solution for generating energy in more and more contexts.
  • Examples of the usage of solar panels include large solar farms producing electricity for a utility company, solar panels deployed at a household (e.g., on a rooftop or near a house), solar panels deployed on a means of locomotion (e.g., a boat or a vehicle), etc.
  • Solar panels come in various form factors and are generally designed so that each solar panel includes a plurality of solar cells. Each solar panel operates as an independent generator of electricity, but several solar panels may be combined to increase the amount of electricity produced.
  • the solar panel is mechanically and electrically connected to a supporting member (e.g., a supporting frame laid on the ground, a wall, a rooftop, etc.).
  • the mechanical connection provides for securing the solar panel to the supporting member and maintaining the solar panel in a predefined position.
  • the electrical connection provides for transferring the electricity generated by the solar panel to the supporting member.
  • the supporting member is generally only an electrical relay having components adapted for transferring the electricity produced by the solar panel to a battery, an electrical motor, an electrical grid, etc.
  • Various mechanisms are used for implementing the mechanical connection between a solar panel and its supporting surface.
  • a basic mechanism consists in simply using screws and nuts (or similar means) for realizing the mechanical connection.
  • the mechanisms used for this mechanical connection generally do not take into account the ease of installation of the solar panel on the supporting surface.
  • a solar panel may be difficult to manipulate by an operator. Therefore, designing a solar panel system including components for facilitating the securing of the solar panel to the receiving surface provides multiple advantages (ease of installation for the operator, minimizing the risks of damaging the solar panel during the installation process, etc.).
  • a solar panel system capable of accommodating solar panels with two rows of solar cells, where each row comprises several solar cells, which can be adapted to the supporting surface to which the solar panels are affixed.
  • the present disclosure provides a coupling assembly for mechanically securing and electrically connecting a solar panel to a pair of rails
  • the coupling assembly comprises a mechanical coupling and an electrical coupling.
  • the mechanical coupling mechanically secures to the solar panel and slides to the pair of rails.
  • the electrical coupling receives two electrical connectors of the solar panel.
  • the electrical coupling module electrically interconnects the two connectors of the solar panel to at least one of: one connector of the solar panel to one of the pair of rails and the other connector of the solar panel to the other rail of the pair of rails, both connectors of the solar panel to one of the rails, one connector of the solar panel to one of the two rails and another connector of the solar panel to a first coupling assembly of an adjacent first solar panel, one of the connector of the solar panel to the first coupling assembly of the adjacent first solar panel and the other connector of the solar panel to a second coupling assembly secured to a second adjacent solar panel, and both connectors of the solar panel to the first coupling assembly of the first solar panel.
  • the electrical coupling of the coupling assembly comprises a conductive pin for providing electrical contact with one of: a conductive strip of one of the rails and a conductive strip of the first coupling assembly of the adjacent first solar panel.
  • the electric coupling of the coupling assembly further comprises a conductive strip for providing electrical contact with a conductive pin of the first coupling assembly of the adjacent first solar panel.
  • the electric coupling of the coupling assembly comprises two conductive pins for providing electrical contact with one of: a conductive strip of one of the rails and a conductive strip of the first coupling assembly of the adjacent first solar panel, two conductive strips of one of the rails, a conductive strip of one of the rails and a conductive strip of another one of the rails, a conductive strip of the first coupling assembly of the adjacent first solar panel and a conductive strip of the second coupling assembly of the adjacent second solar panel.
  • each conductive pin of the coupling assembly is to be electrically connected to a respective one of the electrical connectors of the solar panel.
  • the connectors of the solar panel consist of a pair of bus bars
  • the electrical coupling of the coupling assembly comprises a pair of conductive plates for making electrical contact with the pair of bus bars of the solar panel.
  • the present disclosure provides a structure for mechanically securing and electrically connecting a solar panel having two electrical connectors.
  • the structure comprises a pair of rail and a coupling assembly.
  • the pair of rails is adapted to be mechanically affixed to a solar-powered apparatus. At least one of the rails defines a longitudinal slot.
  • the pair of rails is adapted for interconnecting the solar panel to or through the rails.
  • the coupling assembly is adapted for being mechanically secured to the solar panel.
  • the coupling assembly is adapted to sliding in the longitudinal slot of the at least one rail.
  • the coupling assembly further receives the two electrical connectors of the solar panel and electrically interconnecting the two electrical connectors of the solar panel in one of the following configuration: one connector of the solar panel to one of the two rails and the other connector of the solar panel to the other rail, both connectors of the solar panel to one of the rails, one connector of the solar panel to one of the two rails and another connector of the solar panel to a first coupling assembly of a first adjacent solar panel, one of the connector of the solar panel to the first coupling assembly of the first adjacent solar panel and the other connector of the solar panel to a second coupling assembly secured to a second adjacent solar panel, and both connectors of the solar panel to the first coupling assembly of the first solar panel.
  • the coupling assembly forms a frame surrounding the solar panel.
  • the coupling assembly includes at least one of: a conductive strip and a conductive pin.
  • At least one of the rail further comprises a series of spaced apart conductive strips for electrically contacting with the coupling assembly.
  • the series of spaced apart conductive strips are positioned along the longitudinal slot.
  • the coupling assembly further comprises a conductive pin and at least one of the rails further comprises a plurality of recessed surfaces for mechanically receiving therein the conductive pin of the coupling assembly.
  • both rails of the structure define a longitudinal slot
  • the coupling assembly slides in the longitudinal slot of both rails
  • the structure further comprises four corner elements, each corner element being insertable onto an end of one of the rails.
  • the present disclosure provides a solar panel system comprising a pair of rails, at least one solar panel and a coupling assembly.
  • Each rail of the pair of rails defines at least one longitudinal slot, and one of the rails is further equipped with at least one electrically conductive strip.
  • the at least one solar panel includes a plurality of interconnected solar cells and has electrical connectors.
  • the coupling assembly is affixed to the solar panel and mechanically secures the solar panel by sliding in the longitudinal slot of each one of the rails.
  • the coupling assembly electrically interconnects the two electrical connectors of the solar panel in one of the following configuration: one connector of the solar panel to one of the two rails and the other connector of the solar panel to the other rail, both connectors of the solar panel to one of the rails, one connector of the solar panel to one of the two rails and another connector of the solar panel to a first coupling assembly of a first adjacent solar panel, one of the connector of the solar panel to the first coupling assembly of the first adjacent solar panel and the other connector of the solar panel to a second coupling assembly secured to a second adjacent solar panel, and both connectors of the solar panel to the first coupling assembly of the first solar panel.
  • the pair of rails electrically interconnect the solar panel system to a solar-powered apparatus through the pair of rails.
  • each rail further comprises a securing mechanism for securing the rail to a solar-powered apparatus.
  • each rail is adapted for being secured to a frame of an electrical vehicle.
  • the at least one solar panel includes two independent zones of interconnected solar cells, each zone having electrical connectors, and the coupling assembly electrically interconnects each zone of interconnected solar cells independently to the solar-powered apparatus to or through the rails.
  • solar panel system comprises a plurality of solar panels, the plurality of solar panels are interconnect to the solar- powered apparatus through the coupling assembly in one of the following configuration: in parallel and in series.
  • Figures 1 A-1 E are exemplary schematic configurations of structures and solar panel systems equipped with one or several coupling assemblies, with at least one solar panel and at least one rail;
  • Figure 2A-2D are exemplary schematic configurations of solar panel systems with the present coupling assembly
  • Figure 3 represents a top view of one of the solar panels illustrated in Figure 1 ;
  • Figure 4 represents a perspective view of the solar panel system schematically represented in Figure 2C;
  • Figure 5 represents a front view of an exterior side of one of the coupling assembly and a side view of a solar panel affixed on top;
  • Figures 6A and 6B represent two exemplary schematic electrical connections of the components of the solar panel system, further connected to the solar-powered apparatus;
  • Figures 7A and 7B represent front views of examples of rail
  • Figure 8A represents an exterior front view of an example of coupling assembly
  • Figure 8B represents a front view of an example of complementary slot of the coupling assembly of Figure 8A;
  • Figure 9A represents an example of front view of the coupling assembly of Figure 8A slidably received and mechanically secured to the rail of Figure 7A;
  • Figure 9B represents an example of front view of the coupling assembly of Figure 8A slidably received and mechanically secured to the rail of Figure 7B;
  • Figure 10 represents an example of the coupling assembly of Figure 9A with one edge of a solar panel mechanically secured to the coupling assembly;
  • Figure 11 represents an example of perspective view of the rail of Figure 7A;
  • Figure 12 represents an example of perspective view of the coupling assembly of Figure 8A
  • Figure 13 represents an example of perspective view of the coupling assembly of Figure 12 slidably received and mechanically secured to the rail of Figure 11 ;
  • Figure 14 represents an example of front view of the rail comprising a conductive strip
  • Figure 15 represents an example of conductive pin
  • Figure 16 represents an example of conductive member of the conductive pin of Figure 15;
  • Figure 17 represents a cross-sectional view of an example of the coupling assembly of Figure 8B comprising the conductive pin of Figure 15 in electrical contact with the conductive strip of the rail of Figure 14;
  • Figure 18 represents a partial perspective view of an example of the coupling assembly of Figures 12 and 13 comprising the conductive pin of Figure 15 in electrical contact with the conductive strip of the rail of Figure 14;
  • Figure 19 represents a perspective view of another example of the coupling assembly of Figures 12 and 13 comprising two conductive pins of Figure 15 in electrical contact with consecutive conductive strips of the rail such as shown on Figure 14;
  • Figure 20 represents of cross-sectional view of an example of two adjacent coupling assemblies mechanically secured to a rail, illustrating the electrical contact between respective conductive pins of the coupling assembly and a corresponding electrically conductive strip of the rail;
  • Figures 21 , 22 and 23 represent perspective views of an example of a pair of conductive plates respectively isolated from the coupling assembly illustrated in Figure 20 and integrated to the coupling assembly illustrated in Figure 19;
  • Figure 24 represents a solar panel system according to the present disclosure installed on a light electrical vehicle
  • Figure 25 represents an example of a corner box secured to two adjacent and perpendicular rails.
  • Figures 26A-26C depict three exemplary electrical connection configurations for the present solar panel system.
  • a coupling assembly for mechanically securing and electrically connecting a solar panel to a pair of rails is disclosed, as well as a structure including the coupling assembly and a solar panel system equipped therewith. Th coupling assembly is slidably secured to a pair of rails for mechanical securing and electrical connection of the solar panelis disclosed. Additionally, the solar panel system provides an ergonomic mechanism for electrically connecting the solar panels to the solar-powered apparatus.
  • Coupling assembly an assembly adapted for mechanically coupling a solar panel to a rail or a pair of rails, and electrically coupling the solar panel to the rail or through the rail.
  • Solar panel a group of interconnected solar cells, rigid or flexible, with or without a backing, and provided with at least one pair of electric connectors, namely a positive connector and a negative connector.
  • Solar-powered apparatus any device, vehicle, or construction, either fixed or mobile, which may be powered by solar energy.
  • the present coupling assembly provides mechanical and electrical coupling of a solar panel to a solar-powered apparatus through at least one rail affixed thereto.
  • the present coupling assembly may be attached or affixed directly or indirectly to a solar panel on any of a periphery or backing of the solar panel. Alternately, the present coupling assembly may form a frame which receives either therein, thereon or thereunder the solar panel.
  • the coupling assembly is adapted to be used concurrently with at least one rail. More particularly, the coupling assembly is adapted for sliding into or onto the at least one rail.
  • the coupling assembly further comprises electrical coupling for electrically interconnecting the solar panel to the solar-powered apparatus, either indirectly to the at least one rail, or directly through the at least one rail.
  • the electrical connection of the solar panel to the solar-powered apparatus is completed upon mechanically securing of the solar panel to the rail.
  • Figures 1A-1 E depict exemplary schematic configurations of coupling assemblies, structures equipped therewith and resulting solar panel systems. More precisely, Figure 1 A depict a structure and solar panel system which include one solar panel 100, one coupling assembly 200 and one rail 300. The coupling assembly 200 of Figure 1A is equipped with one mechanical coupling 202 for mechanically securing the solar panel 100 to the rail 300, and one electrical coupling 204 for concurrently electrically interconnecting the solar panel 100 to the rail 300.
  • Figure 1 B represents another exemplary configuration, which include one solar panel 100, one coupling assembly 200 and two rails 300.
  • the coupling assembly 200 is equipped with two mechanical couplings 202 for mechanically securing the solar panel 100 to both rails 300, and one electrical coupling 204 for concurrently electrically interconnecting the connectors (not shown) of the solar panel 100 to one of the rails 300 when the solar panel 100 is mechanically secured to the right-hand side rail 300.
  • Figure 1 C depicts another exemplary configuration, which include one solar panel 100, one coupling assembly 200 and two rails 300.
  • the coupling assembly 200 is equipped with two mechanical couplings 202 for mechanically securing the solar panel 100 to both rails 300, and two electrical couplings 204 for concurrently electrically interconnecting the connectors (not shown) of the solar panel 100 to both of the rails 300 when the solar panel 100 is mechanically secured to the rails 300.
  • the configuration of Figure 1 C allows for example to have a positive connector (not shown) of the solar panel 100 interconnect through the adjacent electrical coupling 204 to one of the rails 300 and a negative connector (not shown) of the solar panel 100 interconnect through the adjacent electrical coupling 204 to the one rail 300.
  • Figure 1 D depicts another exemplary configuration, which include one solar panel 100, one coupling assembly 200 and three rails 300.
  • the coupling assembly 200 is equipped with two mechanical couplings 202 for mechanically securing the solar panel 100 to two opposite rails 300, and one electrical coupling 204 for concurrently electrically interconnecting the connectors (not shown) of the solar panel 100 to the third rail 300 which is perpendicular to the two rails 300 to the solar panel 100 is mechanically secured.
  • Figure 1 E depicts another exemplary configuration, which include two solar panels 100, two coupling assemblies 200 and four rails 300. In the exemplary configuration of Figure 1 E, each solar panel is mechanically and electrically secured by one coupling assembly 200.
  • Each coupling assembly 200 includes two mechanical couplings 204 as shown on Figure 1 D, and two electrical couplings 202.
  • each coupling assembly 200 interconnects one of the connectors (not shown) of the solar panel to one of the rails 300, and the other connector of the solar panel to the other solar panel 100.
  • This particular configuration allows for interconnecting multiple consecutive solar panels through opposing rails 300 which are distinct from the opposing rails 300 used for mechanically securing the solar panels.
  • the configurations of Figures 1 A-1 E are for exemplary purposes only, and although just one solar panel 100 is shown on Figures 1 A-1 D, and two solar panels 100 are shown on Figure 1 E, the present invention is not limited to such numbers of solar panels.
  • Figures 1A-1 E depict the coupling assembly 200 as embedding the solar panel 100, such an implementation is not mandatory and has been used for simplification purposes only.
  • a solar panel 100 could be mechanically secured and electrically interconnected through one coupling assembly 200 including one or multiple electrical couplings 202 and mechanical couplings 204.
  • FIGS 2A-2D depict various configurations of structure and solar panel system equipped with the present coupling assemblies 200.
  • the solar panel system 10 of Figures 2A-2D comprises two solar panels 100.
  • any number of solar panels 100 greater than one can be included in the solar panel system 10.
  • Each solar panel 100 defines a plurality of interconnected solar cells, as will be illustrated later in the description.
  • the rails 300 may also be rigid or flexible.
  • the solar panel system 10 further comprises one coupling assembly 200 for each solar panel 100.
  • the solar panel system 10 of Figure 1 comprises one coupling assembly 200.
  • any number of coupling assemblies 200 greater than one can be included in the solar panel system 10. If the solar panel system 10 comprises N solar panels 100, then the solar panel system 10 comprises any number of coupling assemblies 200 greater than N.
  • the solar panel system 10 further comprises a pair of rails 300.
  • the pair of rails 300 is adapted for mechanically securing and electrically connecting the solar panel system 10 to a solar-powered apparatus 400.
  • the solar panel system 10 is adapted to being installed on various types of solar-powered apparatus 400.
  • an exemplary solar-powered apparatus 400 will consist of a solar-powered vehicle, the solar panel system 10 being mechanically secured to a frame or a surface of the solar-powered vehicle.
  • the solar panel system 10 is adapted to being mechanically secured and electrically interconnected to any type of solar-powered apparatus 400, whether fixed or mobile.
  • the coupling assembly 200 and rails 300 provide mechanical securing and electrical interconnections between the solar panel 100 and the solar- powered apparatus 400, as will be detailed later in the description.
  • the coupling assembly 200 and rails 300 facilitate the installation of the solar panel system 10 on the solar-powered apparatus 400.
  • the solar panel 100 comprises a plurality of solar cells 110.
  • Figure 3 illustrates an exemplary configuration where the solar panel 100 comprises two rows of ten solar cells 110.
  • a person skilled in the art would readily understand that other configurations of solar cells 110 on per solar panel 100 are possible. Any configuration of solar panel 100 comprising N rows and M columns of solar cells 110 for a total of N * M solar cells 110 is within the scope of the present invention.
  • the solar panel system 10 is adapted to support various types of solar panel 100, such as for example laminated solar panels. Therefore, a detailed description of the solar panels 100 is out of the scope of the present disclosure.
  • Figure 4 represents a perspective view of the solar panel system 10 of Figures 2a-2D comprising two solar panels 100 as illustrated in Figure 3, a coupling assembly 200 and the two rails 300.
  • Figure 4 represents solar panels 100 having a flat structure.
  • the solar panel system 10 also supports solar panels 100 defining or tolerating a curvature.
  • the rails 300 and coupling assembly 200 also have a longitudinal curvature, to adapt to a geometrical profile of a surface of the apparatus to which the solar panels are affixed 100 (e.g., a vehicle with a curved rooftop).
  • the coupling assemblies 200 are mounted above the rails 300, but could alternately be mounted below the rails 300 or inside the rails 300.
  • an elongated member may be positioned between the two solar panels 100 for maintaining the two solar panels 100 in position.
  • the elongated member may extend perpendicularly to the rails 300.
  • the elongated member may comprise two opposite longitudinal extrusions, each longitudinal extrusion being adapted for inserting an edge of one of the solar panels 100 therein. If the solar panel system 10 comprises more than two solar panels 100, a longitudinal member may be used for each pair of adjacent solar panels 100.
  • one or multiple solar panels 100 may be inserted into the rails 300.
  • Figure 5 represents a front view of one of the coupling assembly 200 and a side view of one of the solar panels 100.
  • the coupling assembly 200 is adapted for receiving and mechanically securing one edge 105 of a solar panel 100.
  • the edge 105 of the solar panel 100 may be received and mechanically secured to the coupling assembly 200 using any means known in the art.
  • Figure 4 illustrates an embodiment where each solar panel 100 is mechanically secured directly to a coupling assembly 200, wherein the coupling assembly 200 is positioned at one edge 105 of the solar panel 100 and at the opposite edge 105 of the solar panel 100.
  • Figure 5 illustrates a front view of an example of the coupling assembly 200 comprising a housing 201 , the housing 201 defining a surface 205.
  • the surface 205 of the housing 201 is adapted for receiving and mechanically securing the edge 105 of the solar panel 100.
  • the surface 205 is shown as being flat, the surface 205 of this example of the coupling assembly 200 is not limited to such an implementation.
  • the edge 105 of the solar panel 100 may be directly secured to the housing 201 of the coupling assembly 200 or indirectly secured through any means known in the art.
  • the opposite edges 105 of the solar panel 100 may be bonded to two distinct coupling assemblies 200 with an adapted type of glue, where at least a portion of the surface 205 of the housing 201 is glued to the corresponding edge 105 of the solar panel 100.
  • the opposite edges 105 of the solar panel 100 may be welded to one of the pair of coupling assemblies 200 where at least a portion of the surface 205 of the housing 201 is welded to the corresponding edge 105 of the solar panel 100.
  • screws or similar means are used for securing the opposite edges 105 of the solar panel 100 to the pair of coupling assemblies 200.
  • a person skilled in the art would readily understand that other mechanisms may also be used for mechanically securing the solar panel 100 to one of, or both of, the pair of coupling assemblies 200.
  • the solar-powered apparatus 400 comprises a charge 410 (e.g. an electrical battery, an electrical motor, etc.) to be electrically powered by the solar panel system 10.
  • a charge 410 e.g. an electrical battery, an electrical motor, etc.
  • each solar panel 100 represented in Figures 6A and 6B only has eight solar cells 110.
  • a person skilled in the art would readily adapt the electrical circuit represented in Figures 6A and 6B to solar panels 100 comprising any number of solar cells 110.
  • each solar panel 100 is electrically interconnected to form a single panel electrical circuit 111.
  • Each solar panel 100 is mechanically secured to and electrically connected to one or a pair of coupling assemblies 200.
  • a pair of coupling assemblies 200 are associated to a given solar panel 100 to provide mechanical coupling, but only one of the pair of coupling assemblies 200 associated to the solar panel 100 provides electrical coupling.
  • Each solar panel 100 comprises a pair of electrical connectors for electrically connecting the panel electrical circuit 111 formed by the interconnected solar cells 110, to the electrical coupling 202 of the coupling assembly 200.
  • a first group of solar cells 110 of each solar panel 100 (four in the exemplary implementation illustrated in Figure 6B) is electrically interconnected to form a first independent panel electrical circuit 112.
  • a second group of solar cells 110 of each solar panel 100 (the four other ones in the exemplary implementation illustrated in Figure 6B) is electrically interconnected to form a second independent panel electrical circuit 113.
  • the first group of interconnected solar cells 110 of each solar panel 100 (forming the first independent panel electrical circuit 112) is electrically connected to one of the pair of coupling assemblies 200 associated to the solar panel 100.
  • the second group of interconnect solar cells 110 of the solar panel 100 (forming the second independent panel electrical circuit 113) is electrically connected to the other one of the pair of coupling assemblies 200 associated to the solar panel 100.
  • each one of the pair of coupling assemblies 200 associated to a given solar panel 100 simultaneously provides a mechanical coupling and an electrical coupling.
  • Each solar panel 100 comprises a first pair of electrical connectors for interconnecting the first independent panel electrical circuit 112 formed by the first group of interconnected solar cells 110, to a respective pair of electrical connectors of the first coupling assembly 200 electrically connected to the solar panel 100.
  • Each solar panel 100 further comprises a second pair of electrical connectors for interconnecting the second independent panel electrical circuit 113 formed by the second group of interconnected solar cells 110, to a respective pair of electrical connectors comprised in the second coupling assembly 200 electrically connected to the solar panel 100.
  • the configuration of Figure 6B provides a better resilience of each solar panel 100 in terms of solar power capacity.
  • a fault affecting the single electrical circuit of a solar panel 100 prevents the solar panel 100 to generate any solar power.
  • a fault affecting only one of the two independent electrical circuits of a solar panel 100 allows the solar panel 100 to operate at a reduced solar power capacity (e.g. at half capacity).
  • each coupling assembly 200 electrically connected to a solar panel 100 comprises a bypass diode 230 for bypassing the corresponding panel electrical circuit (111 in Figure 6A, 112 and 113 in Figure 6B) of the solar panel 100.
  • Each bypass diode 230 electrically protects the corresponding solar panel 100 and the rest of the electrical circuit from electrical damage. For example, the bypass diode 230 prevents current flow back when there is little or no light reaching the corresponding solar panel 100.
  • Each coupling assembly 200 electrically connected to a solar panel 100 may be further electrically connected to the rail 300 to which it is secured, to electrically connect the charge 410 to the solar panels 100 with the rail(s) 300.
  • the rail 300 and the coupling assemblies 200 secured to this rail 300 are included in the electrical circuit of the solar panel system.
  • the two rails 300 and all the coupling assemblies 200 secured to the two rails 300 are included in the electrical circuit of the solar panel system.
  • Figure 7A represents an exemplary front view of one of the rails 200
  • Figure 8A represents an exemplary front view of one of the coupling assemblies 200
  • Figure 9A represents an exemplary front view of the coupling assembly of Figure 8A slidably received and mechanically secured to the rail of Figure 7A
  • Figure 8A is a simplified version of Figure 5, with the solar panel 100 not being represented.
  • Figure 7B represents an exemplary front view of another exemplary embodiment of rail.
  • Figure 8B represents an exemplary front view of a complementary slot 210 of the coupling assembly 200 illustrated in Figure 8A.
  • Figure 9B represents an exemplary front view of another exemplar of the coupling assembly slidably received and mechanically secured to the rail of Figure 7B.
  • Figures 7A and 7B represent two exemplary embodiments of the rail 300 comprising a frame 301 defining a longitudinal slot 310.
  • Figures 8A and 8B represent the housing 201 of the coupling assembly 200 defining a complementary slot 210 to the rail shown on Figure 7A.
  • the respective designs and shapes of the complementary slot 210 and longitudinal slot 310 may vary.
  • the designs and shapes illustrated in Figures 7A, 7B, 8A and 8B are for illustration purposes only.
  • the frame 301 and housing 201 may be made of various types of materials or combination of materials (e.g., metal, alloy, plastic, etc.).
  • FIGS. 9A and 9B represent two exemplary embodiments of the longitudinal slot 310 slidably receiving and mechanically securing complementary slot 210.
  • Figures 7B and 8B illustrate another exemplary design for the longitudinal slot 310 and complementary slot 210 for providing the functionality of slidably receiving and mechanically securing.
  • the longitudinal slot 310 defines a U-shaped longitudinal member 311 and a central longitudinal member 312 having substantially the shape of a rectangular parallelepiped.
  • the U-shaped longitudinal member 311 and central longitudinal member 312 define two independent longitudinal L shaped channels 313 and 314.
  • the complementary slot 210 is also longitudinal and comprises two longitudinal L shaped members 211 and 212.
  • the two longitudinal L shaped members 211 and 212 define a longitudinal channel 213 of the complementary slot 210.
  • the longitudinal channel 213 has substantially the shape of a rectangular parallelepiped.
  • the longitudinal L shaped members 211 and 212 are slidably insertable into the two independent longitudinal L shaped channels 313 and 314. Furthermore, the complementary shapes of the longitudinal L shaped members 211 and 212, the longitudinal U-shaped member 311 and the central longitudinal member 312 contribute to the mechanical securing functionality (of the complementary slot 210 within the longitudinal slot 310) when the longitudinal L shaped members 211 and 212 are slidably inserted into the two independent longitudinal L shaped channels 313 and 314.
  • the central longitudinal member 312 is slidably insertable into the longitudinal channel 213. Furthermore, the complementary shapes of the two longitudinal L shaped members 211 and 212 and the central longitudinal member 312 contribute to the mechanical securing functionality (of the complementary slot 210 within the longitudinal slot 310) when the central longitudinal member 312 is slidably inserted into the longitudinal channel 213.
  • the frame 301 is shaped as four T-members equally distributed around a center thereof and forming therebetween four isosceles trapezoids longitudinal slots 310.
  • the frame 301 is slidably insertable into the longitudinal channel 213 of the coupling assembly 200, which in this embodiment has an inversed U-shape.
  • the longitudinal channel 213 of the coupling assembly 200 may further include two opposite isosceles trapezoids ridges 315 which contribute to the mechanical securing functionality.
  • the solar panel system 10 comprises N solar panels 100
  • the respective design and shape of the longitudinal slot 310 of the rail 300 are adapted for slidably receiving and mechanically securing N corresponding coupling assemblies 200 (more specifically the complementary slot 210 of the N corresponding coupling assemblies 200).
  • Figure 4 illustrates each rail
  • the 300 being adapted for slidably receiving and mechanically securing 2 coupling assemblies 200.
  • one of the coupling assemblies 200 secured to the solar panel 100 is slidably received and mechanically secured to one of the rails 300 and the other one of the coupling assemblies 200 secured to the given solar panel 100 is slidably received and mechanically secured to the other one of the rails 300.
  • the frame 301 of the rail 300 is further adapted for affixing the frame
  • Figure 7A illustrates an exemplary design of the rail 300, where the frame 301 of the rail 300 defines a lower surface 305 adapted for being positioned on the solar-powered apparatus 400 and affixed to the solar- powered apparatus 400.
  • This exemplary design is adapted for a solar-powered apparatus 400 consisting for example of a flat-roofed vehicle, the rails 300 being affixed on a frame or a roof of the vehicle.
  • various mechanisms may be used for affixing the frame 301 of the rail 300 directly or indirectly to the solar-powered apparatus 400 (e.g., bonding with an adapted type of glue, welding, screwing, legs, supports, etc.).
  • Figure 10 illustrates the coupling assembly 200 with one edge 105 of a solar panel 100 mechanically secured thereto, the coupling assembly 200 being slidably received by a rail 300 for mechanically securing there to.
  • the designs of the coupling assembly 200 and rail 300 are adapted to facilitate the installation of the solar panels 100 on a solar-powered apparatus (not represented in Figure 10 for simplification purposes). More specifically, a solar panel 300 with its two coupling assemblies 200 secured to the solar panel 300 can be easily installed by an operator, by simply sliding the two coupling assemblies 200 into the two corresponding two rails 300 (the two rails 300 having been previously affixed to the solar-powered apparatus).
  • Figure 11 represents a perspective view (corresponding to Figure 7A) of the rail 200.
  • Figure 12 represents a perspective view (corresponding to Figure 8A) of the coupling assembly 200.
  • Figure 13 represents a perspective view (corresponding to Figure 9A) of the coupling assembly of Figure 11 slidably received and mechanically secured to the rail of Figure 11 .
  • At least one electrically conductive strip 340 (represented in Figures 10 and 14) is used. Each electrically conductive strip 340 electrically connects two adjacent coupling assemblies 200.
  • a rail 300 adapted for slidably receiving N coupling assemblies comprises N-1 electrically conductive strips 340.
  • the electrically conductive strip 340 has substantially the shape of a rectangular parallelepiped and is made of an electrically conductive material.
  • a person skilled in the art would readily understand that the shape, size, material and design of the electrically conductive strip 340 may vary, to adapt to the shape, size and material of the rail 300 and of the coupling assemblies 200.
  • FIG. 7A, 7B and 14 a front view of the rail 300 (corresponding to Figure 7A) and a front view of one of the electrically conductive strips 340 are represented in Figure 14.
  • the shape and dimensions of the electrically conductive strip 340 is complementary to the shape of a section of the frame 301 of the rail 300. More specifically, as illustrated in Figures 7A and 7B, a section of the frame 301 defines a recess 320, into which the electrically conductive strip 340 is inserted and mechanically secured as illustrated in Figure 14.
  • the recess 320 is more specifically defined by the central longitudinal member 312 of the longitudinal slot 310 of the rail 300.
  • the shape and dimensions of the electrically conductive strip 340 is also complementary to the shape of a section of the frame 301 of the rail 300, and includes a recess 320, into which the electrically conductive strip 340 is inserted and secured.
  • FIG. 15 a perspective view of an electrically conductive pin 240 is illustrated in Figure 15 and a perspective view of an electrically conductive member 245 of the electrically conductive pin 240 is illustrated in Figure 16.
  • the electrically conductive pin 240 is used for making electrical contact with the electrically conductive strip 340 of the rail 300, thus providing electrical coupling of the solar panel to the rail.
  • the electrically conductive member 245 is made of a conductive material and defines a surface 246 to establish electrical contact with the corresponding electrically conductive strip 340.
  • Figure 10 illustrates the electrically conductive member 245 in contact with electrically conductive strip 340.
  • the electrically conductive pin 240 represented in Figure 15 consists of a push button, comprising a spring 241 and a circular platform 242.
  • the push button 240 provides electrical contact with the corresponding conductive strip 340 of the rail 300 when in a pushed position and does not provide electrical contact with the corresponding conductive strip 340 when in a released position.
  • the design of the electrically conductive pin 240 may vary, to adapt to the design (size and/or shape) of the coupling assembly 200.
  • FIG 17 a cross-sectional view of an example of coupling assembly 200 is provided, and more particularly an example of implementation of the electrical coupling 202.
  • Figure 17 illustrates the electrically conductive pin 240 installed inside the coupling assembly 200.
  • the circular platform 242 provides for positioning the electrically conductive pin 240 within the housing 201 of the coupling assembly 200, and for further securing the electrically conductive pin 240 to the housing 201 .
  • Figure 17 represents the electrically conductive pin 240 in a pushed position, providing electrical contact of the electrically conductive member 245 with the corresponding electrically conductive strip 340 (the rail 300 is not represented in Figure 17 for simplification purposes).
  • the electrical coupling 202 of the coupling assembly 200 is depicted in Figurel 7 as the conductive pin 240, the present invention is not limited to such an implementation, and any component which can electrically couple the solar panel 100 to the rail 300 when the solar panel 100 is mechanically secured to the rail 300 could alternately be used.
  • the example shown in Figure 17 is one possible implementation where the mechanical coupling 204 and the electrical coupling 202 are co-located, but the present invention is not limited to such an implementation, and the mechanical coupling 204 and the electrical coupling 202 could be realized by complementary components.
  • FIG. 18 a partial perspective view of the coupling assembly 200 (corresponding to Figures 12 and 13) is provided in Figure 18.
  • the coupling assembly 200 comprises a removable cover 250.
  • Figure 13 represents the removable cover 250 affixed to the housing 201 of the coupling assembly 200.
  • Figure 18 represents the housing 201 of the coupling assembly 200 without the removable cover 250. Removing the removable cover 250 from the housing 201 provides access to components inside the housing 201 , allowing installation or removal of at least some of the components located inside the housing 201 , such as the electrically conductive pins 240, as well as the aforementioned bypass diodes 230 (represented in Figures 6A and 6B).
  • Figure 18 illustrates one electrically conductive pin 240 installed at one extremity of the coupling assembly 200 inside the housing 201.
  • FIG 19 a complete perspective view of the coupling assembly 200 (at a different angle than in Figure 18) is provided.
  • the coupling assembly 200 is secured to a solar panel 100.
  • Figure 19 illustrates two electrically conductive pins 240 installed at each extremity of the coupling assembly 200 inside the housing 201 .
  • Each electrically conductive pin 240 is positioned to be in electrical contact with a corresponding electrically conductive strip 340 of the rail 300 to which the coupling assembly 200 is mechanically secured (the rail 300 is not represented in Figure 20 for simplification purposes).
  • FIG. 19 a cross-sectional view of two adjacent coupling assemblies 200 mechanically secured to a rail 300 is provided.
  • a first electrically conductive pin 240 is located inside the housing 201 at an extremity of the first coupling assembly 200 (e.g. the left one on Figure 19).
  • the first coupling assembly 200 is secured to a first solar panel 100.
  • a second electrically conductive pin 240 is located inside the housing 201 at an extremity of the second coupling assembly 200 (e.g. the right one on Figure 19).
  • the second coupling assembly 200 is secured to a second solar panel 100.
  • the first and second electrically conductive pins 240 are in electrical contact with the same electrically conductive strip 340 inserted into the rail 300.
  • the first and second solar panels 100 are electrically connected in series via the first and second electrically conductive pins 240, and the electrically conductive strip 340.
  • Figure 20 represents a pair of conductive plates 221 and 222
  • Figure 21 represents the coupling assembly 200 with the conductive plates 221 and 222 therein.
  • the conductive plates 221 and 222 are secured inside the housing 201 of a given coupling assembly 200 to which a given panel 100 is secured.
  • Means for securing the conductive plates 221 and 222 to the housing 201 of the given coupling assembly 200 are well known in the art, and out of the scope of the present disclosure.
  • the conductive plates 221 and 222 may be permanently secured or removably secured.
  • the conductive plates 221 and 222 are an exemplary implementation of the two electrical connectors located inside the housing 201 previously mentioned in the description.
  • An upper section 221 A of the conductive plate 221 is electrically connectable to a first electrical connector of the solar panel 100.
  • An upper section 222A of the conductive plate 222 is electrically connectable to a second electrical connector of the solar panel 100.
  • the coupling assembly 200 comprises two openings 206 and 207 (also represented in Figures 12 and 13).
  • the first and second electrical connectors of the solar panel 100 are respectively inserted inside the coupling assembly 200 via the openings 206 and 207.
  • An exemplary implementation of the first and second electrical connectors of the solar panel 100 consist of respective first and second bus bars.
  • Figure 20 further represents two clips 225 for respectively securing the first electrical connector (e,g the first bus bar) of the solar panel 100 to the upper section 221 A of the conductive plate 221 and the second electrical connector of the solar panel 100 (e.g. the second bus bar) to the upper section 222A of the conductive plate 222.
  • the coupling assembly 200 comprises the first electrically conductive pin 240 (on the left of Figure 22) and the second electrically conductive pin 240 (on the right of Figure 22).
  • a lower section 221 B of the conductive plate 221 is electrically connectable to the first electrically conductive pin 240 (e.g., via a first electrical cable 260 represented in Figure 22).
  • a lower section 222B of the conductive plate 222 is electrically connectable to the second electrically conductive pin 240 (e.g., via a second electrical cable 260 represented in Figure 22).
  • Figure 20 illustrates an electrical current h received from a previous solar panel 100 (via the first electrically conductive pin 240 of Figure 22) being transmitted to the next solar panel via the conductive plate 221 , the electrical current h having circulated in the previous solar panel being received via the conductive plate 222 and being further transmitted to the next solar panel (via the second electrically conductive pin 240 of Figure 22).
  • the design of the conductive plates 221 and 222 is adapted to complete the electrical circuits 111 illustrated in Figure 6A, and to complete the electrical circuits 112 and 113 illustrated in Figure 6B to complete the electrical coupling 202.
  • each coupling assembly 200 comprises a bypass diode 230 located inside the housing 201 of the electrical coupling 202of the coupling assembly 200.
  • the presence of the bypass diode is optional, its presence and purpose is to protect the corresponding solar panel 100 (to which the coupling assembly 200 is affixed) and the rest of the electrical circuit from electrical damage when present.
  • Figure 21 illustrates a box for receiving the bypass diode 230 connecting the first conductive plate 221 to the second conductive plate 222.
  • the electrical current h does not transit through the solar panel 100 electrically connected to the conductive plate 220, the electrical current h directly transits from the first conductive plate 221 to the second conductive plate 222 via the bypass diode 230.
  • additional electric I electronic functionalities are provided by each electrical coupling 202 of the coupling assembly 200, such as controlling I regulating I optimizing I converting the electrical current generated by the solar panel 100 to which the coupling assembly is affixed.
  • additional electric I electronic components are integrated to the conductive plates 221 and 222 or in addition to the conductive plates 221 and 222 for implementing the additional electric / electronic functionalities.
  • FIGs 22 and 23 are simplified views of the inside of the coupling assembly 200 of Figure 20, representing the electrical coupling 200 and more particularly the aforementioned bus bars 121 and 122 respectively connected to the respective corresponding conductive plates 221 (more specifically to the upper section 221 A) and 222 (more specifically to the upper section 222A).
  • the two clips 225 of Figure 21 are not represented for clarity purposes. However, a person skilled in the art would readily understand how the two clips 225 of Figure 21 respectively secure the bus bar 121 to the conductive plate 221 and the bus 122 to the conductive plate 222.
  • FIG. 24 represents the solar panel system 10 installed on a solar-powered apparatus 400 consisting of a light electrical vehicle, illustrated as a golf cart.
  • the solar panel system 10 comprises seven solar panels 100 secured to the two rails 300, via coupling assemblies not represented in Figure 24 for simplification purposes.
  • the two rails 300 are secured to a frame 420 of the light electrical vehicle 400.
  • the light electrical vehicle 400 does not have a rooftop, so that the solar panel system 10 plays the role of a rooftop for the light electrical vehicle 400.
  • two adjacent and perpendicular rails 300 i.e. two abutting rails, are mechanically coupled and, depending on the desired electrical configuration, and optionally electrically interconnected, using a corner box 130 as illustrated.
  • the present structure is not limited to such a design of corner box 130 and any component adapted for mechanically connecting two abutting rails may be used.
  • FIGS 26A-26C depict three exemplary electrical connection configurations of the solar panel system.
  • Figures 26A-26C are simplified diagrams including a plurality of solar panels 100, four rails 300 and one coupling assembly 200 per solar panel 100 in Figure 26A, and two coupling assemblies 200 per solar panel 100 in Figures 26-B and 26C.
  • the exemplary electrical connection configurations could be used for any coupling assembly configuration previously discussed, any structure configuration and any solar panel system previously presented and/or discussed whether or not shown on Figures 26A-26C.
  • Figure 26A shows the solar panels electrically connected on the upper rail only, as electrically represented on Figure 6A.
  • Figure 26B shows the solar panels electrically connected on the upper rail and the lower rail, as depicted on Figure 6B.
  • Figure 26C shows the solar panels electrically connected on the upper rail and the lower rail, where the electrical circuit of the upper rail is electrically connected in series with the electrical circuit of the lower rail through coupling assemblies 200 (not shown on Figure 26C) on both the upper rail and the lower rail.
  • Figures 26A-26C demonstrate how the present solar panel system 10 is flexible and can be installed and configured as solar cells groups.
  • the number of rails 300, corner boxes 130, coupling assemblies 200 and their interconnecting could further be adapted to offer more granularity to the number of solar cells connected as a group and thereby greatly reduce the size of grouped solar cells, and thereby reducing the effects caused by sun shading obstacles.

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Abstract

The present coupling assembly Is adapted for mechanically securing and electrically connecting a solar panel to a pair of rails. The coupling assembly comprises a mechanical coupling securing the solar panel and sliding to the pair of rails. The electrical coupling receives two electrical connectors of the solar panel, and interconnects the two connectors to one of: the pair of rails, one of the rails, one of the two rails and a first coupling assembly of an adjacent first solar panel, the first coupling assembly of the adjacent first solar panel and a second coupling assembly secured to a second adjacent solar panel, and both connectors to the first coupling assembly of the first solar panel.

Description

COUPLING ASSEMBLY FOR A SOLAR PANEL, SOLAR PANEL STRUCTURE AND SOLAR PANEL SYSTEM
TECHNICAL FIELD
[0001] The present disclosure relates to the field of solar panels. More specifically, the present disclosure presents a coupling assembly, structure equipped with such coupling assembly, and a solar panel system.
BACKGROUND
[0002] The manufacturing and deployment of solar panels is becoming an increasingly significant industrial and commercial activity, with solar energy becoming an increasingly cost-effective source of energy. In particular, the combination of innovation and cost reductions makes solar panels an attractive solution for generating energy in more and more contexts. Examples of the usage of solar panels include large solar farms producing electricity for a utility company, solar panels deployed at a household (e.g., on a rooftop or near a house), solar panels deployed on a means of locomotion (e.g., a boat or a vehicle), etc.
[0003] Solar panels come in various form factors and are generally designed so that each solar panel includes a plurality of solar cells. Each solar panel operates as an independent generator of electricity, but several solar panels may be combined to increase the amount of electricity produced. The solar panel is mechanically and electrically connected to a supporting member (e.g., a supporting frame laid on the ground, a wall, a rooftop, etc.). The mechanical connection provides for securing the solar panel to the supporting member and maintaining the solar panel in a predefined position. The electrical connection provides for transferring the electricity generated by the solar panel to the supporting member. The supporting member is generally only an electrical relay having components adapted for transferring the electricity produced by the solar panel to a battery, an electrical motor, an electrical grid, etc. [0004] Various mechanisms are used for implementing the mechanical connection between a solar panel and its supporting surface. A basic mechanism consists in simply using screws and nuts (or similar means) for realizing the mechanical connection. However, the mechanisms used for this mechanical connection generally do not take into account the ease of installation of the solar panel on the supporting surface. Depending on its form factor, dimensions and robustness, a solar panel may be difficult to manipulate by an operator. Therefore, designing a solar panel system including components for facilitating the securing of the solar panel to the receiving surface provides multiple advantages (ease of installation for the operator, minimizing the risks of damaging the solar panel during the installation process, etc.). Furthermore, there is a need for a solar panel system capable of accommodating solar panels with two rows of solar cells, where each row comprises several solar cells, which can be adapted to the supporting surface to which the solar panels are affixed.
[0005] Furthermore, various mechanisms are used for implementing the electrical connection between the solar panel and its supporting surface. For example, electrical cables of the solar panel are usually connected to an electrical box integrated to the supporting member. There is therefore a need for a solar panel system for facilitating the electrical connection of the solar panel to the receiving surface.
[0006] Therefore, there is a need for a new structure, coupling assembly and solar panel system.
SUMMARY
[0007] According to a first aspect, the present disclosure provides a coupling assembly for mechanically securing and electrically connecting a solar panel to a pair of rails, the coupling assembly comprises a mechanical coupling and an electrical coupling. The mechanical coupling mechanically secures to the solar panel and slides to the pair of rails. The electrical coupling receives two electrical connectors of the solar panel. The electrical coupling module electrically interconnects the two connectors of the solar panel to at least one of: one connector of the solar panel to one of the pair of rails and the other connector of the solar panel to the other rail of the pair of rails, both connectors of the solar panel to one of the rails, one connector of the solar panel to one of the two rails and another connector of the solar panel to a first coupling assembly of an adjacent first solar panel, one of the connector of the solar panel to the first coupling assembly of the adjacent first solar panel and the other connector of the solar panel to a second coupling assembly secured to a second adjacent solar panel, and both connectors of the solar panel to the first coupling assembly of the first solar panel.
[0008] According to a particular aspect, the electrical coupling of the coupling assembly comprises a conductive pin for providing electrical contact with one of: a conductive strip of one of the rails and a conductive strip of the first coupling assembly of the adjacent first solar panel.
[0009] According to another particular aspect, the electric coupling of the coupling assembly further comprises a conductive strip for providing electrical contact with a conductive pin of the first coupling assembly of the adjacent first solar panel.
[0010] According to another particular aspect, the electric coupling of the coupling assembly comprises two conductive pins for providing electrical contact with one of: a conductive strip of one of the rails and a conductive strip of the first coupling assembly of the adjacent first solar panel, two conductive strips of one of the rails, a conductive strip of one of the rails and a conductive strip of another one of the rails, a conductive strip of the first coupling assembly of the adjacent first solar panel and a conductive strip of the second coupling assembly of the adjacent second solar panel.
[0011] According to yet another aspect, each conductive pin of the coupling assembly is to be electrically connected to a respective one of the electrical connectors of the solar panel.
[0012] According to another particular aspect, the connectors of the solar panel consist of a pair of bus bars, and the electrical coupling of the coupling assembly comprises a pair of conductive plates for making electrical contact with the pair of bus bars of the solar panel.
[0013] According to a second aspect, the present disclosure provides a structure for mechanically securing and electrically connecting a solar panel having two electrical connectors. The structure comprises a pair of rail and a coupling assembly. The pair of rails is adapted to be mechanically affixed to a solar-powered apparatus. At least one of the rails defines a longitudinal slot. The pair of rails is adapted for interconnecting the solar panel to or through the rails. The coupling assembly is adapted for being mechanically secured to the solar panel. The coupling assembly is adapted to sliding in the longitudinal slot of the at least one rail. The coupling assembly further receives the two electrical connectors of the solar panel and electrically interconnecting the two electrical connectors of the solar panel in one of the following configuration: one connector of the solar panel to one of the two rails and the other connector of the solar panel to the other rail, both connectors of the solar panel to one of the rails, one connector of the solar panel to one of the two rails and another connector of the solar panel to a first coupling assembly of a first adjacent solar panel, one of the connector of the solar panel to the first coupling assembly of the first adjacent solar panel and the other connector of the solar panel to a second coupling assembly secured to a second adjacent solar panel, and both connectors of the solar panel to the first coupling assembly of the first solar panel.
[0014] According to a particular aspect, the coupling assembly forms a frame surrounding the solar panel. [0015] According to another particular aspect, the coupling assembly includes at least one of: a conductive strip and a conductive pin.
[0016] According to another particular aspect, at least one of the rail further comprises a series of spaced apart conductive strips for electrically contacting with the coupling assembly.
[0017] According to another particular aspect, the series of spaced apart conductive strips are positioned along the longitudinal slot.
[0018] According to another particular aspect, the coupling assembly further comprises a conductive pin and at least one of the rails further comprises a plurality of recessed surfaces for mechanically receiving therein the conductive pin of the coupling assembly.
[0019] According to yet another particular aspect, both rails of the structure define a longitudinal slot, the coupling assembly slides in the longitudinal slot of both rails, and the structure further comprises four corner elements, each corner element being insertable onto an end of one of the rails.
[0020] According to a third aspect, the present disclosure provides a solar panel system comprising a pair of rails, at least one solar panel and a coupling assembly. Each rail of the pair of rails defines at least one longitudinal slot, and one of the rails is further equipped with at least one electrically conductive strip. The at least one solar panel includes a plurality of interconnected solar cells and has electrical connectors. The coupling assembly is affixed to the solar panel and mechanically secures the solar panel by sliding in the longitudinal slot of each one of the rails. The coupling assembly electrically interconnects the two electrical connectors of the solar panel in one of the following configuration: one connector of the solar panel to one of the two rails and the other connector of the solar panel to the other rail, both connectors of the solar panel to one of the rails, one connector of the solar panel to one of the two rails and another connector of the solar panel to a first coupling assembly of a first adjacent solar panel, one of the connector of the solar panel to the first coupling assembly of the first adjacent solar panel and the other connector of the solar panel to a second coupling assembly secured to a second adjacent solar panel, and both connectors of the solar panel to the first coupling assembly of the first solar panel.
[0021] According to a particular aspect, the pair of rails electrically interconnect the solar panel system to a solar-powered apparatus through the pair of rails.
[0022] According to a particular aspect, each rail further comprises a securing mechanism for securing the rail to a solar-powered apparatus.
[0023] According to another particular aspect, each rail is adapted for being secured to a frame of an electrical vehicle.
[0024] According to another aspect, the at least one solar panel includes two independent zones of interconnected solar cells, each zone having electrical connectors, and the coupling assembly electrically interconnects each zone of interconnected solar cells independently to the solar-powered apparatus to or through the rails.
[0025] According to another aspect, solar panel system comprises a plurality of solar panels, the plurality of solar panels are interconnect to the solar- powered apparatus through the coupling assembly in one of the following configuration: in parallel and in series. BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Embodiments of the disclosure will be described by way of example only with reference to the accompanying drawings, in which:
[0027] Figures 1 A-1 E are exemplary schematic configurations of structures and solar panel systems equipped with one or several coupling assemblies, with at least one solar panel and at least one rail;
[0028] Figure 2A-2D are exemplary schematic configurations of solar panel systems with the present coupling assembly;
[0029] Figure 3 represents a top view of one of the solar panels illustrated in Figure 1 ;
[0030] Figure 4 represents a perspective view of the solar panel system schematically represented in Figure 2C;
[0031] Figure 5 represents a front view of an exterior side of one of the coupling assembly and a side view of a solar panel affixed on top;
[0032] Figures 6A and 6B represent two exemplary schematic electrical connections of the components of the solar panel system, further connected to the solar-powered apparatus;
[0033] Figures 7A and 7B represent front views of examples of rail;
[0034] Figure 8A represents an exterior front view of an example of coupling assembly;
[0035] Figure 8B represents a front view of an example of complementary slot of the coupling assembly of Figure 8A;
[0036] Figure 9A represents an example of front view of the coupling assembly of Figure 8A slidably received and mechanically secured to the rail of Figure 7A;
[0037] Figure 9B represents an example of front view of the coupling assembly of Figure 8A slidably received and mechanically secured to the rail of Figure 7B;
[0038] Figure 10 represents an example of the coupling assembly of Figure 9A with one edge of a solar panel mechanically secured to the coupling assembly;
[0039] Figure 11 represents an example of perspective view of the rail of Figure 7A;
[0040] Figure 12 represents an example of perspective view of the coupling assembly of Figure 8A;
[0041] Figure 13 represents an example of perspective view of the coupling assembly of Figure 12 slidably received and mechanically secured to the rail of Figure 11 ;
[0042] Figure 14 represents an example of front view of the rail comprising a conductive strip;
[0043] Figure 15 represents an example of conductive pin;
[0044] Figure 16 represents an example of conductive member of the conductive pin of Figure 15;
[0045] Figure 17 represents a cross-sectional view of an example of the coupling assembly of Figure 8B comprising the conductive pin of Figure 15 in electrical contact with the conductive strip of the rail of Figure 14;
[0046] Figure 18 represents a partial perspective view of an example of the coupling assembly of Figures 12 and 13 comprising the conductive pin of Figure 15 in electrical contact with the conductive strip of the rail of Figure 14;
[0047] Figure 19 represents a perspective view of another example of the coupling assembly of Figures 12 and 13 comprising two conductive pins of Figure 15 in electrical contact with consecutive conductive strips of the rail such as shown on Figure 14;
[0048] Figure 20 represents of cross-sectional view of an example of two adjacent coupling assemblies mechanically secured to a rail, illustrating the electrical contact between respective conductive pins of the coupling assembly and a corresponding electrically conductive strip of the rail;
[0049] Figures 21 , 22 and 23 represent perspective views of an example of a pair of conductive plates respectively isolated from the coupling assembly illustrated in Figure 20 and integrated to the coupling assembly illustrated in Figure 19;
[0050] Figure 24 represents a solar panel system according to the present disclosure installed on a light electrical vehicle;
[0051] Figure 25 represents an example of a corner box secured to two adjacent and perpendicular rails; and
[0052] Figures 26A-26C depict three exemplary electrical connection configurations for the present solar panel system.
DETAILED DESCRIPTION
[0053] The foregoing and other features will become more apparent upon reading of the following non-restrictive description of illustrative embodiments thereof, given by way of example only with reference to the accompanying drawings.
[0054] Various aspects of the present disclosure generally address one or more of the problems related to solar panel systems and aim at facilitating installation of solar panels for use with a solar-powered apparatus. In this context, a coupling assembly for mechanically securing and electrically connecting a solar panel to a pair of rails is disclosed, as well as a structure including the coupling assembly and a solar panel system equipped therewith. Th coupling assembly is slidably secured to a pair of rails for mechanical securing and electrical connection of the solar panelis disclosed. Additionally, the solar panel system provides an ergonomic mechanism for electrically connecting the solar panels to the solar-powered apparatus.
[0055] Throughout the present specification, the following expressions are used, and meant to be interpreted as follows:
[0056] Coupling assembly: an assembly adapted for mechanically coupling a solar panel to a rail or a pair of rails, and electrically coupling the solar panel to the rail or through the rail.
[0057] Solar panel: a group of interconnected solar cells, rigid or flexible, with or without a backing, and provided with at least one pair of electric connectors, namely a positive connector and a negative connector.
[0058] Solar-powered apparatus: any device, vehicle, or construction, either fixed or mobile, which may be powered by solar energy.
Exemplary configurations of structures and systems
[0059] The present coupling assembly provides mechanical and electrical coupling of a solar panel to a solar-powered apparatus through at least one rail affixed thereto. The present coupling assembly may be attached or affixed directly or indirectly to a solar panel on any of a periphery or backing of the solar panel. Alternately, the present coupling assembly may form a frame which receives either therein, thereon or thereunder the solar panel. Various examples of coupling assembly implementations will be discussed later. The coupling assembly is adapted to be used concurrently with at least one rail. More particularly, the coupling assembly is adapted for sliding into or onto the at least one rail. Sliding the coupling assembly into or onto the at least one rail mechanically secures the solar panel to the rail thereby mechanically coupling the solar panel to the solar-powered apparatus. The coupling assembly further comprises electrical coupling for electrically interconnecting the solar panel to the solar-powered apparatus, either indirectly to the at least one rail, or directly through the at least one rail. The electrical connection of the solar panel to the solar-powered apparatus is completed upon mechanically securing of the solar panel to the rail.
[0060] Reference is no made Figures 1A-1 E, which depict exemplary schematic configurations of coupling assemblies, structures equipped therewith and resulting solar panel systems. More precisely, Figure 1 A depict a structure and solar panel system which include one solar panel 100, one coupling assembly 200 and one rail 300. The coupling assembly 200 of Figure 1A is equipped with one mechanical coupling 202 for mechanically securing the solar panel 100 to the rail 300, and one electrical coupling 204 for concurrently electrically interconnecting the solar panel 100 to the rail 300. Figure 1 B represents another exemplary configuration, which include one solar panel 100, one coupling assembly 200 and two rails 300. In the configuration shown on Figure 1 B, the coupling assembly 200 is equipped with two mechanical couplings 202 for mechanically securing the solar panel 100 to both rails 300, and one electrical coupling 204 for concurrently electrically interconnecting the connectors (not shown) of the solar panel 100 to one of the rails 300 when the solar panel 100 is mechanically secured to the right-hand side rail 300. Figure 1 C depicts another exemplary configuration, which include one solar panel 100, one coupling assembly 200 and two rails 300. In the exemplary configuration of Figure 1 C, the coupling assembly 200 is equipped with two mechanical couplings 202 for mechanically securing the solar panel 100 to both rails 300, and two electrical couplings 204 for concurrently electrically interconnecting the connectors (not shown) of the solar panel 100 to both of the rails 300 when the solar panel 100 is mechanically secured to the rails 300. The configuration of Figure 1 C allows for example to have a positive connector (not shown) of the solar panel 100 interconnect through the adjacent electrical coupling 204 to one of the rails 300 and a negative connector (not shown) of the solar panel 100 interconnect through the adjacent electrical coupling 204 to the one rail 300. Figure 1 D depicts another exemplary configuration, which include one solar panel 100, one coupling assembly 200 and three rails 300. In the exemplary configuration of Figure 1 D, the coupling assembly 200 is equipped with two mechanical couplings 202 for mechanically securing the solar panel 100 to two opposite rails 300, and one electrical coupling 204 for concurrently electrically interconnecting the connectors (not shown) of the solar panel 100 to the third rail 300 which is perpendicular to the two rails 300 to the solar panel 100 is mechanically secured. Figure 1 E depicts another exemplary configuration, which include two solar panels 100, two coupling assemblies 200 and four rails 300. In the exemplary configuration of Figure 1 E, each solar panel is mechanically and electrically secured by one coupling assembly 200. Each coupling assembly 200 includes two mechanical couplings 204 as shown on Figure 1 D, and two electrical couplings 202. The two electrical couplings 202 of each coupling assembly 200 interconnects one of the connectors (not shown) of the solar panel to one of the rails 300, and the other connector of the solar panel to the other solar panel 100. This particular configuration allows for interconnecting multiple consecutive solar panels through opposing rails 300 which are distinct from the opposing rails 300 used for mechanically securing the solar panels. The configurations of Figures 1 A-1 E are for exemplary purposes only, and although just one solar panel 100 is shown on Figures 1 A-1 D, and two solar panels 100 are shown on Figure 1 E, the present invention is not limited to such numbers of solar panels. Furthermore, although Figures 1A-1 E depict the coupling assembly 200 as embedding the solar panel 100, such an implementation is not mandatory and has been used for simplification purposes only. For example, a solar panel 100 could be mechanically secured and electrically interconnected through one coupling assembly 200 including one or multiple electrical couplings 202 and mechanical couplings 204.
[0061] Reference is now made to Figures 2A-2D, which depict various configurations of structure and solar panel system equipped with the present coupling assemblies 200. For illustration purposes, the solar panel system 10 of Figures 2A-2D comprises two solar panels 100. However, any number of solar panels 100 greater than one can be included in the solar panel system 10. Each solar panel 100 defines a plurality of interconnected solar cells, as will be illustrated later in the description. Although not illustrated, the rails 300 may also be rigid or flexible.
[0062] The solar panel system 10 further comprises one coupling assembly 200 for each solar panel 100. For illustration purposes, the solar panel system 10 of Figure 1 comprises one coupling assembly 200. However, any number of coupling assemblies 200 greater than one can be included in the solar panel system 10. If the solar panel system 10 comprises N solar panels 100, then the solar panel system 10 comprises any number of coupling assemblies 200 greater than N.
[0063] The solar panel system 10 further comprises a pair of rails 300. The pair of rails 300 is adapted for mechanically securing and electrically connecting the solar panel system 10 to a solar-powered apparatus 400. The solar panel system 10 is adapted to being installed on various types of solar-powered apparatus 400. In the rest of the description, an exemplary solar-powered apparatus 400 will consist of a solar-powered vehicle, the solar panel system 10 being mechanically secured to a frame or a surface of the solar-powered vehicle. However, a person skilled in the art would readily understand that the solar panel system 10 is adapted to being mechanically secured and electrically interconnected to any type of solar-powered apparatus 400, whether fixed or mobile.
[0064] The coupling assembly 200 and rails 300 provide mechanical securing and electrical interconnections between the solar panel 100 and the solar- powered apparatus 400, as will be detailed later in the description. The coupling assembly 200 and rails 300 facilitate the installation of the solar panel system 10 on the solar-powered apparatus 400.
[0065] Reference is now made concurrently to Figure 3, which represents a top view of one of the solar panels 100.
[0066] The solar panel 100 comprises a plurality of solar cells 110. Figure 3 illustrates an exemplary configuration where the solar panel 100 comprises two rows of ten solar cells 110. A person skilled in the art would readily understand that other configurations of solar cells 110 on per solar panel 100 are possible. Any configuration of solar panel 100 comprising N rows and M columns of solar cells 110 for a total of N * M solar cells 110 is within the scope of the present invention. More generally, the solar panel system 10 is adapted to support various types of solar panel 100, such as for example laminated solar panels. Therefore, a detailed description of the solar panels 100 is out of the scope of the present disclosure.
[0067] Reference is now made concurrently to Figures 2A-2D, 3 and 4, where Figure 4 represents a perspective view of the solar panel system 10 of Figures 2a-2D comprising two solar panels 100 as illustrated in Figure 3, a coupling assembly 200 and the two rails 300.
[0068] Figure 4 represents solar panels 100 having a flat structure. However, the solar panel system 10 also supports solar panels 100 defining or tolerating a curvature. Optionally, the rails 300 and coupling assembly 200 also have a longitudinal curvature, to adapt to a geometrical profile of a surface of the apparatus to which the solar panels are affixed 100 (e.g., a vehicle with a curved rooftop). On Figure 4, the coupling assemblies 200 are mounted above the rails 300, but could alternately be mounted below the rails 300 or inside the rails 300.
[0069] In a configuration not represented in Figure 4 for simplification purposes, an elongated member may be positioned between the two solar panels 100 for maintaining the two solar panels 100 in position. The elongated member may extend perpendicularly to the rails 300. The elongated member may comprise two opposite longitudinal extrusions, each longitudinal extrusion being adapted for inserting an edge of one of the solar panels 100 therein. If the solar panel system 10 comprises more than two solar panels 100, a longitudinal member may be used for each pair of adjacent solar panels 100.
[0070] In another configuration not shown in Figure 4, one or multiple solar panels 100 may be inserted into the rails 300.
[0071] Reference is now made concurrently to Figures 2A-2D, 4, and 5, where Figure 5 represents a front view of one of the coupling assembly 200 and a side view of one of the solar panels 100. The coupling assembly 200 is adapted for receiving and mechanically securing one edge 105 of a solar panel 100. The edge 105 of the solar panel 100 may be received and mechanically secured to the coupling assembly 200 using any means known in the art. [0072] Figure 4 illustrates an embodiment where each solar panel 100 is mechanically secured directly to a coupling assembly 200, wherein the coupling assembly 200 is positioned at one edge 105 of the solar panel 100 and at the opposite edge 105 of the solar panel 100.
[0073] Figure 5 illustrates a front view of an example of the coupling assembly 200 comprising a housing 201 , the housing 201 defining a surface 205. In this example, the surface 205 of the housing 201 is adapted for receiving and mechanically securing the edge 105 of the solar panel 100. Although the surface 205 is shown as being flat, the surface 205 of this example of the coupling assembly 200 is not limited to such an implementation. Furthermore, the edge 105 of the solar panel 100 may be directly secured to the housing 201 of the coupling assembly 200 or indirectly secured through any means known in the art. In this particular example of coupling assembly, the opposite edges 105 of the solar panel 100 may be bonded to two distinct coupling assemblies 200 with an adapted type of glue, where at least a portion of the surface 205 of the housing 201 is glued to the corresponding edge 105 of the solar panel 100. In another example, the opposite edges 105 of the solar panel 100 may be welded to one of the pair of coupling assemblies 200 where at least a portion of the surface 205 of the housing 201 is welded to the corresponding edge 105 of the solar panel 100. In still another example, screws (or similar means) are used for securing the opposite edges 105 of the solar panel 100 to the pair of coupling assemblies 200. A person skilled in the art would readily understand that other mechanisms may also be used for mechanically securing the solar panel 100 to one of, or both of, the pair of coupling assemblies 200.
[0074] Reference is now made concurrently to Figures 2A-2D, 6A and 6B, where Figures 6A and 6B represent two different schematic implementations of electrical interconnections of the solar panel system 10 to the solar-powered apparatus 400.
[0075] The solar-powered apparatus 400 comprises a charge 410 (e.g. an electrical battery, an electrical motor, etc.) to be electrically powered by the solar panel system 10.
[0076] For simplification purposes, each solar panel 100 represented in Figures 6A and 6B only has eight solar cells 110. However, a person skilled in the art would readily adapt the electrical circuit represented in Figures 6A and 6B to solar panels 100 comprising any number of solar cells 110.
[0077] In the configuration of Figure 6A, all the solar cells 110 of each solar panel 100 are electrically interconnected to form a single panel electrical circuit 111. Each solar panel 100 is mechanically secured to and electrically connected to one or a pair of coupling assemblies 200. Thus, in this configuration, a pair of coupling assemblies 200 are associated to a given solar panel 100 to provide mechanical coupling, but only one of the pair of coupling assemblies 200 associated to the solar panel 100 provides electrical coupling.
[0078] Each solar panel 100 comprises a pair of electrical connectors for electrically connecting the panel electrical circuit 111 formed by the interconnected solar cells 110, to the electrical coupling 202 of the coupling assembly 200.
[0079] In the configuration of Figure 6B, a first group of solar cells 110 of each solar panel 100 (four in the exemplary implementation illustrated in Figure 6B) is electrically interconnected to form a first independent panel electrical circuit 112. A second group of solar cells 110 of each solar panel 100 (the four other ones in the exemplary implementation illustrated in Figure 6B) is electrically interconnected to form a second independent panel electrical circuit 113. The first group of interconnected solar cells 110 of each solar panel 100 (forming the first independent panel electrical circuit 112) is electrically connected to one of the pair of coupling assemblies 200 associated to the solar panel 100. The second group of interconnect solar cells 110 of the solar panel 100 (forming the second independent panel electrical circuit 113) is electrically connected to the other one of the pair of coupling assemblies 200 associated to the solar panel 100. Thus, in this configuration, each one of the pair of coupling assemblies 200 associated to a given solar panel 100 simultaneously provides a mechanical coupling and an electrical coupling. [0080] Each solar panel 100 comprises a first pair of electrical connectors for interconnecting the first independent panel electrical circuit 112 formed by the first group of interconnected solar cells 110, to a respective pair of electrical connectors of the first coupling assembly 200 electrically connected to the solar panel 100. Each solar panel 100 further comprises a second pair of electrical connectors for interconnecting the second independent panel electrical circuit 113 formed by the second group of interconnected solar cells 110, to a respective pair of electrical connectors comprised in the second coupling assembly 200 electrically connected to the solar panel 100.
[0081] The configuration of Figure 6B provides a better resilience of each solar panel 100 in terms of solar power capacity. For example, in the configuration of Figure 6A, a fault affecting the single electrical circuit of a solar panel 100 prevents the solar panel 100 to generate any solar power. In the configuration of Figure 6B, a fault affecting only one of the two independent electrical circuits of a solar panel 100 allows the solar panel 100 to operate at a reduced solar power capacity (e.g. at half capacity).
[0082] Optionally, each coupling assembly 200 electrically connected to a solar panel 100 comprises a bypass diode 230 for bypassing the corresponding panel electrical circuit (111 in Figure 6A, 112 and 113 in Figure 6B) of the solar panel 100. Each bypass diode 230 electrically protects the corresponding solar panel 100 and the rest of the electrical circuit from electrical damage. For example, the bypass diode 230 prevents current flow back when there is little or no light reaching the corresponding solar panel 100.
[0083] Each coupling assembly 200 electrically connected to a solar panel 100 may be further electrically connected to the rail 300 to which it is secured, to electrically connect the charge 410 to the solar panels 100 with the rail(s) 300. In the configuration of Figure 6A, only one rail 300 and the coupling assemblies 200 secured to this rail 300 are included in the electrical circuit of the solar panel system. In the configuration of Figure 6B, the two rails 300 and all the coupling assemblies 200 secured to the two rails 300 are included in the electrical circuit of the solar panel system.
[0084] Reference is now made concurrently to Figures 1, 4, 7A, 7B, 8A, 8B, 9A and 9B, where Figure 7A represents an exemplary front view of one of the rails 200, Figure 8A represents an exemplary front view of one of the coupling assemblies 200, and Figure 9A represents an exemplary front view of the coupling assembly of Figure 8A slidably received and mechanically secured to the rail of Figure 7A. Figure 8A is a simplified version of Figure 5, with the solar panel 100 not being represented. Figure 7B represents an exemplary front view of another exemplary embodiment of rail. Figure 8B represents an exemplary front view of a complementary slot 210 of the coupling assembly 200 illustrated in Figure 8A. Figure 9B represents an exemplary front view of another exemplar of the coupling assembly slidably received and mechanically secured to the rail of Figure 7B.
[0085] Figures 7A and 7B represent two exemplary embodiments of the rail 300 comprising a frame 301 defining a longitudinal slot 310. Figures 8A and 8B represent the housing 201 of the coupling assembly 200 defining a complementary slot 210 to the rail shown on Figure 7A. The respective designs and shapes of the complementary slot 210 and longitudinal slot 310 may vary. The designs and shapes illustrated in Figures 7A, 7B, 8A and 8B are for illustration purposes only. Furthermore, the frame 301 and housing 201 may be made of various types of materials or combination of materials (e.g., metal, alloy, plastic, etc.).
[0086] The respective designs and shapes of the longitudinal slot 310 and complementary slot 210 are adapted, so that the longitudinal slot 310 may slidably receive and mechanically secure the complementary slot 210. Figures 9A and 9B represent two exemplary embodiments of the longitudinal slot 310 slidably receiving and mechanically securing complementary slot 210.
[0087] Figures 7B and 8B illustrate another exemplary design for the longitudinal slot 310 and complementary slot 210 for providing the functionality of slidably receiving and mechanically securing. [0088] In the exemplary design shown on Figures 7A and 8A, the longitudinal slot 310 defines a U-shaped longitudinal member 311 and a central longitudinal member 312 having substantially the shape of a rectangular parallelepiped. The U-shaped longitudinal member 311 and central longitudinal member 312 define two independent longitudinal L shaped channels 313 and 314.
[0089] The complementary slot 210 is also longitudinal and comprises two longitudinal L shaped members 211 and 212. The two longitudinal L shaped members 211 and 212 define a longitudinal channel 213 of the complementary slot 210. The longitudinal channel 213 has substantially the shape of a rectangular parallelepiped.
[0090] The longitudinal L shaped members 211 and 212 are slidably insertable into the two independent longitudinal L shaped channels 313 and 314. Furthermore, the complementary shapes of the longitudinal L shaped members 211 and 212, the longitudinal U-shaped member 311 and the central longitudinal member 312 contribute to the mechanical securing functionality (of the complementary slot 210 within the longitudinal slot 310) when the longitudinal L shaped members 211 and 212 are slidably inserted into the two independent longitudinal L shaped channels 313 and 314.
[0091] The central longitudinal member 312 is slidably insertable into the longitudinal channel 213. Furthermore, the complementary shapes of the two longitudinal L shaped members 211 and 212 and the central longitudinal member 312 contribute to the mechanical securing functionality (of the complementary slot 210 within the longitudinal slot 310) when the central longitudinal member 312 is slidably inserted into the longitudinal channel 213.
[0092] In the exemplary design shown on Figures 7B and 9B, the frame 301 is shaped as four T-members equally distributed around a center thereof and forming therebetween four isosceles trapezoids longitudinal slots 310.
[0093] The frame 301 is slidably insertable into the longitudinal channel 213 of the coupling assembly 200, which in this embodiment has an inversed U-shape. The longitudinal channel 213 of the coupling assembly 200 may further include two opposite isosceles trapezoids ridges 315 which contribute to the mechanical securing functionality.
[0094] Furthermore, if the solar panel system 10 comprises N solar panels 100, then the respective design and shape of the longitudinal slot 310 of the rail 300 are adapted for slidably receiving and mechanically securing N corresponding coupling assemblies 200 (more specifically the complementary slot 210 of the N corresponding coupling assemblies 200). For example, Figure 4 illustrates each rail
300 being adapted for slidably receiving and mechanically securing 2 coupling assemblies 200. For any given solar panel 100, one of the coupling assemblies 200 secured to the solar panel 100 is slidably received and mechanically secured to one of the rails 300 and the other one of the coupling assemblies 200 secured to the given solar panel 100 is slidably received and mechanically secured to the other one of the rails 300.
[0095] The frame 301 of the rail 300 is further adapted for affixing the frame
301 to the solar-powered apparatus 400 (not represented in Figures 7A, 8A, 9A and 9B for simplification purposes). Figure 7A illustrates an exemplary design of the rail 300, where the frame 301 of the rail 300 defines a lower surface 305 adapted for being positioned on the solar-powered apparatus 400 and affixed to the solar- powered apparatus 400. This exemplary design is adapted for a solar-powered apparatus 400 consisting for example of a flat-roofed vehicle, the rails 300 being affixed on a frame or a roof of the vehicle.
[0096] As mentioned previously, various mechanisms may be used for affixing the frame 301 of the rail 300 directly or indirectly to the solar-powered apparatus 400 (e.g., bonding with an adapted type of glue, welding, screwing, legs, supports, etc.).
[0097] Reference is now particularly made to Figure 10, where Figure 10 corresponds to Figures 5 and 9A. Figure 10 illustrates the coupling assembly 200 with one edge 105 of a solar panel 100 mechanically secured thereto, the coupling assembly 200 being slidably received by a rail 300 for mechanically securing there to.
[0098] The designs of the coupling assembly 200 and rail 300 are adapted to facilitate the installation of the solar panels 100 on a solar-powered apparatus (not represented in Figure 10 for simplification purposes). More specifically, a solar panel 300 with its two coupling assemblies 200 secured to the solar panel 300 can be easily installed by an operator, by simply sliding the two coupling assemblies 200 into the two corresponding two rails 300 (the two rails 300 having been previously affixed to the solar-powered apparatus).
[0099] Reference is now made concurrently to Figures 11, 12 and 13. Figure 11 represents a perspective view (corresponding to Figure 7A) of the rail 200. Figure 12 represents a perspective view (corresponding to Figure 8A) of the coupling assembly 200. Figure 13 represents a perspective view (corresponding to Figure 9A) of the coupling assembly of Figure 11 slidably received and mechanically secured to the rail of Figure 11 .
[00100] Reference is now made concurrently to Figures 7A, 10, 13, 14, 15, 16, 17, 18, 19 and 20, where these Figures illustrate a mechanism for electrically connecting the coupling assemblies 200 to the rail 300 to which they are mechanically secured.
[00101] With respect to the rail 300, at least one electrically conductive strip 340 (represented in Figures 10 and 14) is used. Each electrically conductive strip 340 electrically connects two adjacent coupling assemblies 200. Thus, a rail 300 adapted for slidably receiving N coupling assemblies comprises N-1 electrically conductive strips 340.
[00102] In the exemplary implementation illustrated in the Figures, the electrically conductive strip 340 has substantially the shape of a rectangular parallelepiped and is made of an electrically conductive material. A person skilled in the art would readily understand that the shape, size, material and design of the electrically conductive strip 340 may vary, to adapt to the shape, size and material of the rail 300 and of the coupling assemblies 200.
[00103] Referring more particularly to Figures 7A, 7B and 14, a front view of the rail 300 (corresponding to Figure 7A) and a front view of one of the electrically conductive strips 340 are represented in Figure 14. The shape and dimensions of the electrically conductive strip 340 is complementary to the shape of a section of the frame 301 of the rail 300. More specifically, as illustrated in Figures 7A and 7B, a section of the frame 301 defines a recess 320, into which the electrically conductive strip 340 is inserted and mechanically secured as illustrated in Figure 14.
[00104] In the exemplary implementation illustrated in Figure 7A, the recess 320 is more specifically defined by the central longitudinal member 312 of the longitudinal slot 310 of the rail 300. Although not shown on Figure 7B, the shape and dimensions of the electrically conductive strip 340 is also complementary to the shape of a section of the frame 301 of the rail 300, and includes a recess 320, into which the electrically conductive strip 340 is inserted and secured.
[00105] Referring more particularly to Figures 15 and 16, a perspective view of an electrically conductive pin 240 is illustrated in Figure 15 and a perspective view of an electrically conductive member 245 of the electrically conductive pin 240 is illustrated in Figure 16. The electrically conductive pin 240 is used for making electrical contact with the electrically conductive strip 340 of the rail 300, thus providing electrical coupling of the solar panel to the rail.
[00106] The electrically conductive member 245 is made of a conductive material and defines a surface 246 to establish electrical contact with the corresponding electrically conductive strip 340. Figure 10 illustrates the electrically conductive member 245 in contact with electrically conductive strip 340. A person skilled in the art would readily understand that the design of the electrically conductive member 245 may vary. [00107] The electrically conductive pin 240 represented in Figure 15 consists of a push button, comprising a spring 241 and a circular platform 242. The push button 240 provides electrical contact with the corresponding conductive strip 340 of the rail 300 when in a pushed position and does not provide electrical contact with the corresponding conductive strip 340 when in a released position. A person skilled in the art would readily understand that the design of the electrically conductive pin 240 may vary, to adapt to the design (size and/or shape) of the coupling assembly 200.
[00108] Referring more particularly to Figure 17, a cross-sectional view of an example of coupling assembly 200 is provided, and more particularly an example of implementation of the electrical coupling 202. Figure 17 illustrates the electrically conductive pin 240 installed inside the coupling assembly 200. The circular platform 242 provides for positioning the electrically conductive pin 240 within the housing 201 of the coupling assembly 200, and for further securing the electrically conductive pin 240 to the housing 201 . Figure 17 represents the electrically conductive pin 240 in a pushed position, providing electrical contact of the electrically conductive member 245 with the corresponding electrically conductive strip 340 (the rail 300 is not represented in Figure 17 for simplification purposes). Although the electrical coupling 202 of the coupling assembly 200 is depicted in Figurel 7 as the conductive pin 240, the present invention is not limited to such an implementation, and any component which can electrically couple the solar panel 100 to the rail 300 when the solar panel 100 is mechanically secured to the rail 300 could alternately be used. The example shown in Figure 17 is one possible implementation where the mechanical coupling 204 and the electrical coupling 202 are co-located, but the present invention is not limited to such an implementation, and the mechanical coupling 204 and the electrical coupling 202 could be realized by complementary components.
[00109] Referring more particularly to Figures 13 and 18, a partial perspective view of the coupling assembly 200 (corresponding to Figures 12 and 13) is provided in Figure 18. The coupling assembly 200 comprises a removable cover 250. Figure 13 represents the removable cover 250 affixed to the housing 201 of the coupling assembly 200. Figure 18 represents the housing 201 of the coupling assembly 200 without the removable cover 250. Removing the removable cover 250 from the housing 201 provides access to components inside the housing 201 , allowing installation or removal of at least some of the components located inside the housing 201 , such as the electrically conductive pins 240, as well as the aforementioned bypass diodes 230 (represented in Figures 6A and 6B). Figure 18 illustrates one electrically conductive pin 240 installed at one extremity of the coupling assembly 200 inside the housing 201.
[00110] Referring more particularly to Figure 19, a complete perspective view of the coupling assembly 200 (at a different angle than in Figure 18) is provided. The coupling assembly 200 is secured to a solar panel 100. Figure 19 illustrates two electrically conductive pins 240 installed at each extremity of the coupling assembly 200 inside the housing 201 . Each electrically conductive pin 240 is positioned to be in electrical contact with a corresponding electrically conductive strip 340 of the rail 300 to which the coupling assembly 200 is mechanically secured (the rail 300 is not represented in Figure 20 for simplification purposes).
[00111] Referring more particularly to Figure 19, a cross-sectional view of two adjacent coupling assemblies 200 mechanically secured to a rail 300 is provided. A first electrically conductive pin 240 is located inside the housing 201 at an extremity of the first coupling assembly 200 (e.g. the left one on Figure 19). The first coupling assembly 200 is secured to a first solar panel 100. A second electrically conductive pin 240 is located inside the housing 201 at an extremity of the second coupling assembly 200 (e.g. the right one on Figure 19). The second coupling assembly 200 is secured to a second solar panel 100. The first and second electrically conductive pins 240 are in electrical contact with the same electrically conductive strip 340 inserted into the rail 300. The first and second solar panels 100 are electrically connected in series via the first and second electrically conductive pins 240, and the electrically conductive strip 340.
[00112] Reference is now made concurrently to Figures 19, 20 and 21 , where Figure 20 represents a pair of conductive plates 221 and 222, and Figure 21 represents the coupling assembly 200 with the conductive plates 221 and 222 therein.
[00113] As illustrated in Figures 19 and 21 , the conductive plates 221 and 222 are secured inside the housing 201 of a given coupling assembly 200 to which a given panel 100 is secured. Means for securing the conductive plates 221 and 222 to the housing 201 of the given coupling assembly 200 are well known in the art, and out of the scope of the present disclosure. The conductive plates 221 and 222 may be permanently secured or removably secured.
[00114] The conductive plates 221 and 222 are an exemplary implementation of the two electrical connectors located inside the housing 201 previously mentioned in the description. An upper section 221 A of the conductive plate 221 is electrically connectable to a first electrical connector of the solar panel 100. An upper section 222A of the conductive plate 222 is electrically connectable to a second electrical connector of the solar panel 100.
[00115] As illustrated in Figure 18, the coupling assembly 200 comprises two openings 206 and 207 (also represented in Figures 12 and 13). The first and second electrical connectors of the solar panel 100 are respectively inserted inside the coupling assembly 200 via the openings 206 and 207. An exemplary implementation of the first and second electrical connectors of the solar panel 100 consist of respective first and second bus bars. Figure 20 further represents two clips 225 for respectively securing the first electrical connector (e,g the first bus bar) of the solar panel 100 to the upper section 221 A of the conductive plate 221 and the second electrical connector of the solar panel 100 (e.g. the second bus bar) to the upper section 222A of the conductive plate 222.
[00116] As illustrated in Figure 22, the coupling assembly 200 comprises the first electrically conductive pin 240 (on the left of Figure 22) and the second electrically conductive pin 240 (on the right of Figure 22). A lower section 221 B of the conductive plate 221 is electrically connectable to the first electrically conductive pin 240 (e.g., via a first electrical cable 260 represented in Figure 22). A lower section 222B of the conductive plate 222 is electrically connectable to the second electrically conductive pin 240 (e.g., via a second electrical cable 260 represented in Figure 22).
[00117] Figure 20 illustrates an electrical current h received from a previous solar panel 100 (via the first electrically conductive pin 240 of Figure 22) being transmitted to the next solar panel via the conductive plate 221 , the electrical current h having circulated in the previous solar panel being received via the conductive plate 222 and being further transmitted to the next solar panel (via the second electrically conductive pin 240 of Figure 22).
[00118] The design of the conductive plates 221 and 222 is adapted to complete the electrical circuits 111 illustrated in Figure 6A, and to complete the electrical circuits 112 and 113 illustrated in Figure 6B to complete the electrical coupling 202.
[00119] As mentioned previously, each coupling assembly 200 comprises a bypass diode 230 located inside the housing 201 of the electrical coupling 202of the coupling assembly 200. Although the presence of the bypass diode is optional, its presence and purpose is to protect the corresponding solar panel 100 (to which the coupling assembly 200 is affixed) and the rest of the electrical circuit from electrical damage when present.
[00120] Figure 21 illustrates a box for receiving the bypass diode 230 connecting the first conductive plate 221 to the second conductive plate 222. When the electrical current h does not transit through the solar panel 100 electrically connected to the conductive plate 220, the electrical current h directly transits from the first conductive plate 221 to the second conductive plate 222 via the bypass diode 230. [00121] Optionally, additional electric I electronic functionalities are provided by each electrical coupling 202 of the coupling assembly 200, such as controlling I regulating I optimizing I converting the electrical current generated by the solar panel 100 to which the coupling assembly is affixed. In an exemplary configuration, additional electric I electronic components are integrated to the conductive plates 221 and 222 or in addition to the conductive plates 221 and 222 for implementing the additional electric / electronic functionalities.
[00122] Reference is now made to Figures 22 and 23, which are simplified views of the inside of the coupling assembly 200 of Figure 20, representing the electrical coupling 200 and more particularly the aforementioned bus bars 121 and 122 respectively connected to the respective corresponding conductive plates 221 (more specifically to the upper section 221 A) and 222 (more specifically to the upper section 222A). The two clips 225 of Figure 21 are not represented for clarity purposes. However, a person skilled in the art would readily understand how the two clips 225 of Figure 21 respectively secure the bus bar 121 to the conductive plate 221 and the bus 122 to the conductive plate 222.
[00123] Reference is now made concurrently to Figure 24, which represents the solar panel system 10 installed on a solar-powered apparatus 400 consisting of a light electrical vehicle, illustrated as a golf cart.
[00124] The solar panel system 10 comprises seven solar panels 100 secured to the two rails 300, via coupling assemblies not represented in Figure 24 for simplification purposes. The two rails 300 are secured to a frame 420 of the light electrical vehicle 400. The light electrical vehicle 400 does not have a rooftop, so that the solar panel system 10 plays the role of a rooftop for the light electrical vehicle 400.
[00125] In another embodiment shown on Figures 1 D, 1 E and 25, two adjacent and perpendicular rails 300, i.e. two abutting rails, are mechanically coupled and, depending on the desired electrical configuration, and optionally electrically interconnected, using a corner box 130 as illustrated. The present structure is not limited to such a design of corner box 130 and any component adapted for mechanically connecting two abutting rails may be used.
[00126] Reference is now made to Figures 26A-26C which depict three exemplary electrical connection configurations of the solar panel system. Figures 26A-26C are simplified diagrams including a plurality of solar panels 100, four rails 300 and one coupling assembly 200 per solar panel 100 in Figure 26A, and two coupling assemblies 200 per solar panel 100 in Figures 26-B and 26C. The exemplary electrical connection configurations could be used for any coupling assembly configuration previously discussed, any structure configuration and any solar panel system previously presented and/or discussed whether or not shown on Figures 26A-26C. Figure 26A shows the solar panels electrically connected on the upper rail only, as electrically represented on Figure 6A. Figure 26B shows the solar panels electrically connected on the upper rail and the lower rail, as depicted on Figure 6B. Figure 26C shows the solar panels electrically connected on the upper rail and the lower rail, where the electrical circuit of the upper rail is electrically connected in series with the electrical circuit of the lower rail through coupling assemblies 200 (not shown on Figure 26C) on both the upper rail and the lower rail. Figures 26A-26C demonstrate how the present solar panel system 10 is flexible and can be installed and configured as solar cells groups. Although not shown on Figures 26A-26C, the number of rails 300, corner boxes 130, coupling assemblies 200 and their interconnecting could further be adapted to offer more granularity to the number of solar cells connected as a group and thereby greatly reduce the size of grouped solar cells, and thereby reducing the effects caused by sun shading obstacles.
[00127] Although the present disclosure has been described hereinabove by way of non-restrictive, illustrative embodiments thereof, these embodiments may be modified at will within the scope of the appended claims without departing from the spirit and nature of the present disclosure.

Claims

WHAT IS CLAIMED IS:
1 . A structure for mechanically securing and electrically connecting a solar panel having two electrical connectors, the structure comprising: a pair of rails to be mechanically affixed to a solar-powered apparatus, at least one of the rails defining a longitudinal slot; a coupling assembly for mechanically securing to the solar panel and sliding in the longitudinal slot of the at least one rail, the coupling assembly further receiving the two electrical connectors of the solar panel and electrically interconnecting the two electrical connectors of the solar panel in one of the following configuration: one connector of the solar panel to one of the two rails and the other connector of the solar panel to the other rail, both connectors of the solar panel to one of the rails, one connector of the solar panel to one of the two rails and another connector of the solar panel to a first coupling assembly of a first adjacent solar panel, one of the connector of the solar panel to the first coupling assembly of the first adjacent solar panel and the other connector of the solar panel to a second coupling assembly secured to a second adjacent solar panel, and both connectors of the solar panel to the first coupling assembly of the first solar panel.
2. The structure of claim 1 , wherein the coupling assembly forms a frame surrounding the solar panel.
3. The structure of claim 2, wherein the coupling assembly includes at least one of: a conductive strip and a conductive pin.
4. The structure of claim 2, wherein at least one of the rails further comprises a series of spaced apart conductive strips for electrically contacting with the coupling assembly.
5. The structure of claim 4, wherein the series of spaced apart conductive strips are positioned along the longitudinal slot. The structure of claim 1 , wherein the coupling assembly further comprises an conductive pin and at least one of the rails further comprises a plurality of recessed surfaces for mechanically receiving therein the conductive pin of the coupling assembly. The structure of claim 1 , wherein: both rails define a longitudinal slot; the coupling assembly slides in the longitudinal slot of both rails; and the structure further comprises four corner elements, each corner element being insertable onto an end of one of the rails. A coupling assembly for mechanically securing and electrically connecting a solar panel to a pair of rails, the coupling assembly comprising: a mechanical coupling for mechanically securing to the solar panel and sliding to the pair of rails; an electrical coupling for receiving two electrical connectors of the solar panel, the electrical coupling module electrically interconnecting the two connectors of the solar panel to at least one of: one connector of the solar panel to one of the pair of rails and the other connector of the solar panel to the other rai of the pair of rails, both connectors of the solar panel to one of the rails, one connector of the solar panel to one of the two rails and another connector of the solar panel to a first coupling assembly of an adjacent first solar panel, one of the connector of the solar panel to the first coupling assembly of the adjacent first solar panel and the other connector of the solar panel to a second coupling assembly secured to a second adjacent solar panel, and both connectors of the solar panel to the first coupling assembly of the first solar panel. The coupling assembly of claim 8, wherein the electrical coupling comprises a conductive pin for providing electrical contact with one of: a conductive strip of one of the rails and a conductive strip of the first coupling assembly of the adjacent first solar panel. The coupling assembly of claim 8, wherein the electric coupling further comprises a conductive strip for providing electrical contact with a conductive pin of the first coupling assembly of the adjacent first solar panel. The coupling assembly claim 8, wherein the electric coupling comprises two conductive pins for providing electrical contact with one of: a conductive strip of one of the rails and a conductive strip of the first coupling assembly of the adjacent first solar panel, two conductive strips of one of the rails, a conductive strip of one of the rails and a conductive strip of another one of the rails, a conductive strip of the first coupling assembly of the adjacent first solar panel and a conductive strip of the second coupling assembly of the adjacent second solar panel. The coupling assembly of claim 11 , wherein each conductive pin is to be electrically connected to a respective one of the electrical connectors of the solar panel. The coupling assembly of claim 8, wherein the electrical coupling comprises a pair of conductive plates for making electrical contact with a pair of bus bars of the solar panel. A solar panel system comprising: a pair of rails, each rail defining at least one longitudinal slot, one of the rails being further equipped with at least one electrically conductive strip; at least one solar panel including a plurality of interconnected solar cells and having electrical connectors; and a coupling assembly for mechanically securing to the solar panel by sliding in the longitudinal slot of each one of the rails, the coupling assembly electrically interconnecting the two electrical connectors of the solar panel in one of the following configuration: one connector of the solar panel to one of the two rails and the other connector of the solar panel to the other rail, both connectors of the solar panel to one of the rails, one connector of the solar panel to one of the two rails and another connector of the solar panel to a first coupling assembly of a first adjacent solar panel, one of the connector of the solar panel to the first coupling assembly of the first adjacent solar panel and the other connector of the solar panel to a second coupling assembly secured to a second adjacent solar panel, and both connectors of the solar panel to the first coupling assembly of the first solar panel. The solar panel system of claim 14, wherein the pair of rails electrically interconnect the solar panel system to a solar-powered apparatus. The solar panel system of claim 14, wherein each rail further comprises a securing mechanism for securing the rail to a solar-powered apparatus. The solar panel system of claim 14, wherein each rail is adapted for being secured to a frame of an electrical vehicle. The solar panel system of claim 14, wherein: the at least one solar panel includes two independent zones of interconnected solar cells, each zone having electrical connectors; the coupling assembly electrically interconnecting each zone of interconnected solar cells independently. The solar panel system of claim 14, comprising a plurality of solar panels, the plurality of solar panels being interconnect to the solar-powered apparatus through the coupling assembly in one of the following configurations: in parallel and in series.
PCT/CA2023/051302 2022-10-04 2023-10-02 Coupling assembly for a solar panel, solar panel structure and solar panel system WO2024073840A1 (en)

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